JP2009004670A - Drum-type inductor and its manufacturing method - Google Patents

Drum-type inductor and its manufacturing method Download PDF

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JP2009004670A
JP2009004670A JP2007165841A JP2007165841A JP2009004670A JP 2009004670 A JP2009004670 A JP 2009004670A JP 2007165841 A JP2007165841 A JP 2007165841A JP 2007165841 A JP2007165841 A JP 2007165841A JP 2009004670 A JP2009004670 A JP 2009004670A
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magnetic
resin
drum
coil
winding
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Hiroshi Kuribayashi
寛 栗林
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Tokin Corp
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NEC Tokin Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a drum-type and small inductor which satisfies a high inductance and a low resistance at the same time and to provide its manufacturing method. <P>SOLUTION: The inductor is formed by applying a magnetic resin 2 which is a homogeneous mixture of a magnetic powder 5 and a resin 6 at a constant compounding ratio for covering the periphery 1a of a coil 3 and lateral flange peripheries 1b and the flange surface 1c of a drum core 1 when needed. Also, the magnetic resin 2 is dried and hardened while permanent magnets 4 are arranged on one or both flange surfaces 1c of the drum core 1. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、携帯機器等の小型電子機器に使用されるドラム型インダクタに関するものである。   The present invention relates to a drum type inductor used in a small electronic device such as a portable device.

ドラム型インダクタは、２つの鍔部を有し、該鍔に挟まれた凹状の巻線部を有するドラム型磁芯（以下、「ドラムコア」と呼ぶ）の該巻線部に直にコイルを巻線して構成する開磁路型インダクタで、機器内を流れる電圧・電流の尖頭値を抑え、周辺部品への電気ストレスを軽減させる、いわゆる平滑用として用いられる重要電子部品である。   The drum-type inductor has two flange portions, and a coil is wound directly on the winding portion of a drum-type magnetic core (hereinafter referred to as “drum core”) having a concave winding portion sandwiched between the flanges. This is an important electronic component used for so-called smoothing that suppresses the peak value of the voltage and current flowing in the device and reduces the electrical stress on the peripheral components by an open magnetic circuit type inductor constituted by wires.

また、ドラム型インダクタは、磁芯に直にコイルを巻線して構成するので、小型化が容易で、かつ低コストで製造できることから、特に小型機器への搭載には好適で、広い用途・市場を有している。   In addition, the drum-type inductor is configured by winding a coil directly on a magnetic core, so it is easy to downsize and can be manufactured at low cost. Has a market.

近年、電子機器の低電圧・大電流化が進んでおり、それに伴い機器内のインダクタへの対応要求も厳しくなっている。インダクタにおいては、特に大電流化への対応が重要となる。大電流化によって電流の尖頭値は大きくなるので、その尖頭値を抑え平滑化するために高インダクタンス化が求められる。また同時に、コイルの巻線抵抗成分による損失・発熱と電源効率の低下を抑えるために低抵抗化も求められる。   In recent years, electronic devices have become low voltage and large current, and accordingly, the requirement for handling inductors in the devices has become strict. In an inductor, it is particularly important to cope with a large current. Since the peak value of the current increases as the current increases, a high inductance is required to suppress and smooth the peak value. At the same time, a reduction in resistance is also required in order to suppress loss and heat generation due to the winding resistance component of the coil and a decrease in power supply efficiency.

図３は、従来のドラム型インダクタを説明する図である。図３（ａ）は上面図、図３（ｂ）は断面図、図３（ｃ）は磁性樹脂塗布部の拡大断面図をそれぞれ示す。従来のドラム型インダクタでは、インダクタンス特性を向上させるために、図３（ｂ）、図３（ｃ）に示すように、磁性粉末５が約３０ｖｏｌ％の配合比で、樹脂６と均一に混合させた磁性樹脂２を、コイル３が巻かれたドラムコア１の両鍔内縁部を覆い囲むように塗布・充填して、磁性樹脂塗布部８を形成し、閉磁路型構造としている。この際、磁性樹脂２の磁性粉末５の分布状態は、磁性粉末間距離Ａが均一に離れた状態で分布する。このようなドラム型インダクタは、例えば特許文献１に開示されている。   FIG. 3 is a diagram for explaining a conventional drum-type inductor. FIG. 3A is a top view, FIG. 3B is a cross-sectional view, and FIG. 3C is an enlarged cross-sectional view of the magnetic resin coating portion. In the conventional drum type inductor, in order to improve the inductance characteristics, as shown in FIGS. 3B and 3C, the magnetic powder 5 is uniformly mixed with the resin 6 at a blending ratio of about 30 vol%. The magnetic resin 2 is applied and filled so as to cover both inner edges of the drum core 1 around which the coil 3 is wound, thereby forming the magnetic resin application portion 8 to form a closed magnetic circuit type structure. At this time, the distribution state of the magnetic powder 5 of the magnetic resin 2 is distributed in a state where the distance A between the magnetic powders is uniformly separated. Such a drum-type inductor is disclosed in, for example, Patent Document 1.

特開２００７−６７０８１号公報JP 2007-67081 A

上述した、従来のドラム型インダクタでは、ドラムコアの両鍔に挟まれた巻線部に巻かれたコイルの外周部を覆うように磁性樹脂を塗布・充填し、閉磁路を形成する構造となっており、磁性樹脂中の磁性粉末の配合比率を上げることで、磁性樹脂中の磁性粉末間距離を狭くして実効透磁率を上げ、高いインダクタンスを得ることが可能となるが、一方では、磁性樹脂の粘度が高くなると、磁性樹脂塗布時の作業効率が悪化すると共に、ドラムコアに巻かれたコイル細部への磁性樹脂充填性が悪化し、硬化後の磁性樹脂部の固着強度が脆くなって、剥がれや砕け落ちが生じ易くなるという欠点があった。このような事由から、磁性粉末量の配合比率には限界があり、約４０ｖｏｌ％程度が上限とされている。従って、上記方法による高インダクタンス化には限界があった。   The conventional drum type inductor described above has a structure in which a closed magnetic circuit is formed by applying and filling a magnetic resin so as to cover the outer periphery of the coil wound around the winding portion sandwiched between both ends of the drum core. By increasing the blending ratio of the magnetic powder in the magnetic resin, it is possible to increase the effective magnetic permeability by narrowing the distance between the magnetic powders in the magnetic resin and obtain a high inductance. When the viscosity of the magnetic resin increases, the work efficiency at the time of applying the magnetic resin deteriorates, the magnetic resin filling property to the coil details wound around the drum core deteriorates, and the fixing strength of the magnetic resin portion after curing becomes brittle and peels off. In addition, there was a drawback that breakage easily occurs. For these reasons, there is a limit to the blending ratio of the magnetic powder amount, and the upper limit is about 40 vol%. Therefore, there is a limit to increasing the inductance by the above method.

更に高いインダクタンスを得ようとした場合には、ドラムコアに巻線されたコイルの巻回数を増やすしか方法が無く、その結果、巻線コイルの直流抵抗が増大したり、又直流抵抗の増大を抑えるため巻線コイルの線径を大きくしたりしなければならず、製品外形寸法が増大するという問題があった。従って、小型形状で、かつ直流抵抗の増加を抑え、高いインダクタンスを実現することは不可能であった。   In order to obtain a higher inductance, the only way to increase the number of turns of the coil wound around the drum core is to increase the DC resistance of the winding coil or to suppress the increase in DC resistance. Therefore, the wire diameter of the winding coil has to be increased, and there has been a problem that the outer dimensions of the product increase. Therefore, it has been impossible to realize a high inductance with a small shape and with suppressed increase in DC resistance.

従って、本発明は、小型形状、高インダクタンス、低抵抗を同時に満足するドラム型インダクタとその製造方法の提供を目的とする。   Accordingly, an object of the present invention is to provide a drum-type inductor that satisfies both a compact shape, a high inductance, and a low resistance, and a manufacturing method thereof.

本発明は、上記の課題を解決すべく、ドラム型インダクタのドラムコア両鍔に挟まれた凹状巻線部に巻線されたコイルの外周部全体を覆うように磁性樹脂を塗布して閉磁路型インダクタを形成し、更に磁性樹脂の硬化時は、ドラムコアの前記コイルの巻線中心軸方向に直交する面上である鍔部表面に永久磁石を配した状態で行うことで、磁性樹脂中の磁性粉末が、磁化されたドラムコア側に引き寄せられ、磁性樹脂のコイルに近い部分である内側が最も密、コイルから離れた部分である外側が最も疎の分布状態で硬化する。   In order to solve the above-mentioned problems, the present invention applies a magnetic resin so as to cover the entire outer periphery of a coil wound around a concave winding portion sandwiched between both drum cores of a drum-type inductor, thereby providing a closed magnetic circuit type. When an inductor is formed and the magnetic resin is hardened, a permanent magnet is arranged on the surface of the collar portion on the surface perpendicular to the winding center axis direction of the coil of the drum core, so that the magnetism in the magnetic resin is increased. The powder is attracted to the magnetized drum core side, and hardens in a distribution state in which the inner part, which is a part close to the coil of the magnetic resin, is the densest and the outer part, which is a part away from the coil, is the most sparse.

その結果、磁束は磁性粉末が密集して磁性粉末間距離が狭い、狭ギャップ構造で形成される、コイル近傍を通ることになり平均磁路長が短くなる。その結果、コイルの巻回数を増やさずに、更に高いインダクタンス特性を得ることが可能となり、同時にコイルの直流抵抗増加及び製品形状の大型化を抑えることができる。   As a result, the magnetic flux is densely packed, the distance between the magnetic powders is narrow, and the magnetic flux passes through the vicinity of the coil, which has a narrow gap structure, and the average magnetic path length is shortened. As a result, even higher inductance characteristics can be obtained without increasing the number of turns of the coil, and at the same time, an increase in the DC resistance of the coil and an increase in the size of the product can be suppressed.

また、ドラムコアの前記コイルの巻線中心軸方向に直交する面である鍔部表面もしくはその上面に配置する永久磁石の磁力を調整することで、磁性粉末の分布密度のみならず、磁気配向性も制御することが可能となり、インダクタンス特性の制御も可能となる。   Further, by adjusting the magnetic force of the permanent magnet disposed on the surface of the collar portion or the upper surface thereof that is perpendicular to the winding central axis direction of the coil of the drum core, not only the distribution density of the magnetic powder but also the magnetic orientation It is possible to control the inductance characteristics.

更には、ドラムコアの鍔部側周部付近では磁性樹脂中の磁性粉末密度が低く、樹脂密度が高くなることから、磁性樹脂とドラムコアとの固着強度も高めることができる。   Furthermore, since the magnetic powder density in the magnetic resin is low and the resin density is high in the vicinity of the flange side periphery of the drum core, the fixing strength between the magnetic resin and the drum core can be increased.

本発明によれば、２つの鍔部と、前記鍔部に挟まれた巻線部を有するドラム型磁芯の、前記巻線部にコイルを形成してなるインダクタであって、少なくとも前記コイルの外周部を覆うように磁性粉末と樹脂を混合した磁性樹脂を配してなり、前記磁性樹脂は、前記外周部の前記コイルに近い部分の磁性粉末密度が、前記コイルから離れた部分の磁性粉末密度よりも高いことを特徴とするドラム型インダクタが得られる。   According to the present invention, there is provided an inductor formed by forming a coil in the winding portion of a drum-type magnetic core having two winding portions and a winding portion sandwiched between the flange portions, and at least of the coil A magnetic resin mixed with magnetic powder and resin is disposed so as to cover the outer peripheral portion, and the magnetic resin has a magnetic powder density in a portion near the coil in the outer peripheral portion and a magnetic powder in a portion away from the coil. A drum type inductor characterized by being higher than the density is obtained.

本発明によれば、２つの鍔部と、前記鍔部に挟まれた巻線部を有するドラム型磁芯の、前記巻線部にコイルを形成し、少なくとも前記コイルの外周部を覆うように磁性粉末と樹脂を混合した磁性樹脂を配し、前記鍔部の前記コイルの巻線中心軸方向に直交する面上に永久磁石を配した状態で、前記磁性樹脂を硬化したことを特徴とするドラム型インダクタの製造方法が得られる。   According to the present invention, a coil is formed in the winding portion of a drum-type magnetic core having two flange portions and a winding portion sandwiched between the flange portions so as to cover at least the outer peripheral portion of the coil. A magnetic resin mixed with magnetic powder and a resin is disposed, and the magnetic resin is cured in a state where a permanent magnet is disposed on a surface orthogonal to the winding central axis direction of the coil of the flange portion. A method for manufacturing a drum-type inductor is obtained.

本発明によれば、前記磁性粉末の特性と、前記磁性粉末と前記樹脂の混合比率と、前記永久磁石の磁気特性から選択された、少なくとも２つの要素を組み合わせることによりインダクタンス特性を調整することを特徴とするドラム型インダクタの製造方法が得られる。   According to the present invention, the inductance characteristic is adjusted by combining at least two elements selected from the characteristics of the magnetic powder, the mixing ratio of the magnetic powder and the resin, and the magnetic characteristics of the permanent magnet. A method for manufacturing a drum-type inductor is obtained.

以上述べたように、本発明により、ドラム型インダクタのコイル外周部と、必要に応じてドラムコアの鍔部側周部と鍔部表面を覆うように磁性樹脂を塗布して閉磁路を形成するインダクタにおいて、磁性樹脂の硬化時にドラムコアの鍔部の一方又は両方の表面に永久磁石を設置した状態で硬化することで、磁性樹脂中の磁性粉末は、磁化されたドラムコア側に引き寄せられ、同時に磁性粉末同士の間隔も狭くなって、インダクタの実効透磁率が上がる為、コイル巻回数を増やすことなく、高いインダクタンスを得ることが可能となり、直流抵抗の増加及び製品形状の大型化を抑えることができる。更には、磁性樹脂部の固着強度も向上させることができる。   As described above, according to the present invention, an inductor that forms a closed magnetic circuit by applying a magnetic resin so as to cover the outer periphery of the coil of the drum-type inductor and, if necessary, the flange-side periphery and the flange surface of the drum core. In this case, the magnetic powder in the magnetic resin is attracted to the magnetized drum core side by curing the magnetic resin in a state where a permanent magnet is installed on one or both surfaces of the flange part of the drum core when the magnetic resin is cured. Since the gap between them is narrowed and the effective magnetic permeability of the inductor is increased, a high inductance can be obtained without increasing the number of coil turns, and an increase in DC resistance and an increase in product shape can be suppressed. Furthermore, the fixing strength of the magnetic resin portion can also be improved.

また、インダクタンスの調整方法として、これまでの磁性粉末の磁気特性と配合比率を各々変更する方法に加え、永久磁石の磁気特性を変更する方法も可能となる。従って、磁性粉末の磁気特性と、磁性粉末と樹脂の混合比率と、更に永久磁石の磁気特性から選択された、少なくとも２つの要素を組み合わせることによりインダクタンス特性を高精密に、かつ効率よく調整することが可能となる。   Further, as a method of adjusting the inductance, in addition to the conventional method of changing the magnetic characteristics and the blending ratio of the magnetic powder, a method of changing the magnetic characteristics of the permanent magnet is also possible. Therefore, the inductance characteristics can be adjusted with high precision and efficiency by combining at least two elements selected from the magnetic characteristics of the magnetic powder, the mixing ratio of the magnetic powder and the resin, and the magnetic characteristics of the permanent magnet. Is possible.

本発明の実施の形態について図面を用いて説明する。   Embodiments of the present invention will be described with reference to the drawings.

図１は、本発明のドラム型インダクタとその製造方法を説明する図である。図１（ａ）は上面図、図１（ｂ）は断面図、図１（ｃ）は磁性樹脂塗布部の拡大断面図をそれぞれ示す。   FIG. 1 is a diagram for explaining a drum type inductor according to the present invention and a manufacturing method thereof. 1A is a top view, FIG. 1B is a cross-sectional view, and FIG. 1C is an enlarged cross-sectional view of a magnetic resin coating portion.

図１（ａ）、図１（ｂ）で示すように、ドラムコア１の鍔部に挟まれた巻線部にコイル３を形成した後、該コイル３の外周部１ａおよび該ドラムコア１の鍔部側周部１ｂを覆うように、磁性粉末５と樹脂６を任意の配合比率で混合した磁性樹脂２を塗布して磁性樹脂塗布部８を形成し、更にドラムコア１の巻線中心軸方向に直交する面である鍔部表面１ｃに永久磁石４を配置した状態で乾燥・硬化させる。   As shown in FIG. 1A and FIG. 1B, after the coil 3 is formed in the winding portion sandwiched between the flange portions of the drum core 1, the outer peripheral portion 1a of the coil 3 and the flange portion of the drum core 1 are formed. A magnetic resin coating portion 8 is formed by applying magnetic resin 2 in which magnetic powder 5 and resin 6 are mixed at an arbitrary blending ratio so as to cover side peripheral portion 1 b, and further perpendicular to the winding central axis direction of drum core 1. The permanent magnet 4 is dried and hardened in a state where the permanent magnet 4 is disposed on the collar surface 1c that is a surface to be worked.

その結果、図１（ｃ）に示すように、磁性樹脂２の磁性粉末５は、永久磁石４によって磁化されたドラムコア１の鍔部側周部１ｂとコイル３の外周部１ａに引き寄せられて、磁性粉末間距離Ｂが狭く接近した状態で分布する。従って、狭ギャップ構造が形成されて、インダクタの実効透磁率が上がり、高いインダクタンスを得ることができる。   As a result, as shown in FIG. 1C, the magnetic powder 5 of the magnetic resin 2 is attracted to the flange side peripheral portion 1b of the drum core 1 magnetized by the permanent magnet 4 and the outer peripheral portion 1a of the coil 3. It is distributed in a state where the distance B between the magnetic powders is narrow and close. Therefore, a narrow gap structure is formed, the effective permeability of the inductor is increased, and a high inductance can be obtained.

図２は、本発明のドラム型インダクタの平均磁路長を説明する図である。平均磁路長とは、インダクタの形状に起因する磁気定数で、インダクタンス特性に大きく影響するもので、長いとインダクタンスは小さく、短いとインダクタンスは大きくなる。   FIG. 2 is a diagram for explaining the average magnetic path length of the drum-type inductor according to the present invention. The average magnetic path length is a magnetic constant attributed to the shape of the inductor and greatly affects the inductance characteristics. When the length is long, the inductance is small, and when the length is short, the inductance is large.

図２（ａ）は、磁性樹脂２の硬化時に永久磁石４を配置しない場合の平均磁路長を示す図であり、磁性樹脂２の磁性粉末５は均一に分布しているので、磁束は磁性樹脂２の塗布厚のほぼ中央部を通ることになり、平均磁路長７は長くなることがわかる。   FIG. 2A is a diagram showing an average magnetic path length when the permanent magnet 4 is not disposed when the magnetic resin 2 is cured. Since the magnetic powder 5 of the magnetic resin 2 is uniformly distributed, the magnetic flux is magnetic. It can be seen that the average magnetic path length 7 becomes longer because the resin 2 passes almost the center of the coating thickness.

一方、図２（ｂ）は、磁性樹脂２の硬化時にドラムコア１の鍔部表面１ｃに永久磁石４を配置した場合の平均磁路長を示す図であり、磁性樹脂２の磁性粉末５はコイル３の外周部１ａに密集するので、磁束はその箇所を通ることになり、平均磁路長７は短くなることがわかる。   On the other hand, FIG. 2B is a diagram showing the average magnetic path length when the permanent magnet 4 is arranged on the flange surface 1c of the drum core 1 when the magnetic resin 2 is cured, and the magnetic powder 5 of the magnetic resin 2 is a coil. 3 is concentrated in the outer peripheral portion 1a, so that the magnetic flux passes through the portion, and the average magnetic path length 7 is shortened.

上述のドラムコア１の材質は、Ｎｉ−Ｚｎ系フェライト材としているが、Ｍｎ−Ｚｎ系フェライト材でもよく、圧粉ダストコア等、どんな磁性材料でもよい。   The material of the drum core 1 is a Ni—Zn ferrite material, but may be a Mn—Zn ferrite material or any magnetic material such as a dust core.

上述のドラムコア１の中脚部及び鍔部の形状は、共に断面が円形の円板状としているが、方形状や多角形状、または楕円や長円形等の断面を持つ板状であれば、何れの形状でもよい。但し、ドラムコアに直に巻線する構造であることから、巻線材の絶縁皮膜への機械的損傷を避けるために、特に中脚部については角部の無い円形断面の円柱状とするのが望ましい。   The shape of the middle leg portion and the collar portion of the drum core 1 described above is a disc shape with a circular cross section. However, any shape may be used as long as it is a square shape, a polygonal shape, or a plate shape having a cross section such as an ellipse or an oval shape. The shape may be acceptable. However, since the structure is wound directly on the drum core, in order to avoid mechanical damage to the insulating film of the winding material, it is desirable to make the middle leg part a cylindrical shape with a circular cross section without corners. .

上述の磁性樹脂２は、磁性粉末５と樹脂６の配合比率を４０ｖｏｌ％としたが、樹脂６自体の初期粘度との兼ね合いも影響するので、選定する樹脂によって適宜、配合比率を調整するのが望ましい。インダクタンスを高めるために、磁性粉末５の配合比率を上げると、粘性が低下し、塗布作業性や、ドラムコアとコイルとの接着性が低下し脆くなる。従って、磁性粉末の配合比率を２０〜８０％程度の範囲内がよいが、４０〜７０％程度が好適である。また、低粘度樹脂を用いるとなおよい。また、塗布位置については、少なくともコイルの外周部１ａが覆われていればよく、ドラムコアの鍔部側周部１ｂや鍔部表面１ｃは覆われていても、露出していてもよい。   In the magnetic resin 2 described above, the blending ratio of the magnetic powder 5 and the resin 6 is 40 vol%. However, since the balance with the initial viscosity of the resin 6 itself is also affected, the blending ratio is appropriately adjusted depending on the resin to be selected. desirable. When the blending ratio of the magnetic powder 5 is increased in order to increase the inductance, the viscosity is lowered, and the coating workability and the adhesion between the drum core and the coil are lowered and become brittle. Therefore, the blending ratio of the magnetic powder is preferably in the range of about 20 to 80%, but about 40 to 70% is preferable. It is even better to use a low viscosity resin. Moreover, about the application | coating position, the outer peripheral part 1a of a coil should just be covered, and the collar part side peripheral part 1b and collar part surface 1c of a drum core may be covered, or may be exposed.

上述のコイル３は、一般的な円形断面の絶縁被覆銅線を用いているが、方形や長円形の断面を持つ平角銅線等を用いてもよい。   Although the above-mentioned coil 3 uses the insulation coating copper wire of a general circular cross section, you may use the rectangular copper wire etc. which have a square or an oval cross section.

上述の永久磁石４は、フェライト、金属、希土類などの焼結磁石や、樹脂と混合したボンド磁石等の汎用品でよく、磁力を調整できるよう、適宜、材質、形状、寸法を選定するのが望ましい。形状については、加工性、取扱作業性なども考慮し、棒状の直方体や長円体形状が好適である。寸法は、ドラムコア１の鍔部表面１ｃの全面を覆うに足りる大きさを有していればよい。また、着磁方法は上記鍔部表面１ｃに対して垂直方向とするのが望ましい。更に、配置方法は、ここではドラムコアの鍔部表面１ｃに直に密着させているが、量産性や永久磁石の脱着作業性などを考慮して、ドラムコアと永久磁石との間に冶具等を介して鍔部表面１ｃから少し離した状態で配置してもよい。   The permanent magnet 4 described above may be a general-purpose product such as a sintered magnet made of ferrite, metal, rare earth, or a bonded magnet mixed with resin, and the material, shape, and dimensions are appropriately selected so that the magnetic force can be adjusted. desirable. Regarding the shape, a rod-shaped rectangular parallelepiped or an ellipsoidal shape is suitable in consideration of workability, handling workability, and the like. The dimension should just have a magnitude | size sufficient to cover the whole surface of the collar part surface 1c of the drum core 1. FIG. Further, it is desirable that the magnetizing method is a direction perpendicular to the flange surface 1c. Furthermore, although the arrangement method here is in direct contact with the collar surface 1c of the drum core, a jig or the like is interposed between the drum core and the permanent magnet in consideration of mass productivity and workability of attaching and detaching the permanent magnet. It may be arranged in a state slightly separated from the flange surface 1c.

上述の磁性粉末５は、Ｎｉ−Ｚｎ系やＭｎ−Ｚｎ系のフェライト粉末、鉄、コバルト、ニッケル等の金属粉末、またそれらの配合比を適宜調整して混合したアモルファス、パーマロイ、センダスト等の合金粉末の何れでもよい。   The magnetic powder 5 includes Ni-Zn and Mn-Zn ferrite powders, metal powders such as iron, cobalt, and nickel, and alloys such as amorphous, permalloy, and sendust that are mixed by appropriately adjusting their blending ratio. Any of powder may be sufficient.

上述の樹脂６は、エポキシ系などの熱硬化性や紫外線硬化性等の粘性樹脂が好適であり、塗布性、作業性を考慮し、適宜、材質や粘度を選定するのが望ましい。   The resin 6 described above is preferably an epoxy-based viscous resin such as thermosetting or ultraviolet curable, and it is desirable to select the material and viscosity appropriately in consideration of applicability and workability.

ドラムコア１は、透磁率４００、鍔部の外径φ３．８ｍｍ、鍔部厚み０．５ｍｍ、中脚径φ１．８ｍｍ、高さ１．５ｍｍのＮｉ−Ｚｎ系フェライトコアを用いて、コイル３は、線材が線径φ０．１６ｍｍのポリウレタン被覆銅線を使用し、巻回数を１０ターンとした。磁性樹脂２はエポキシ系熱硬化性樹脂（品名：Ｓ７０、レジナス化成社）に磁性粉末５が鉄系アモルファス粉末を４０ｖｏｌ％の配合比率で混合し、コイル３の外周部１ａとドラムコア１の鍔部側周部１ｂを覆うようにディスペンサで塗布した。永久磁石４は、大きさφ５×３ｍｍ円板状で、厚み方向に着磁され磁力が５テスラのネオジ系希土類磁石を用意し、ドラムコア１の一方の鍔部表面１ｃに直に密着させ、恒温槽に入れて乾燥・硬化させて、図１に示した本発明のドラム型インダクタを得た。   The drum core 1 uses a Ni-Zn ferrite core having a magnetic permeability of 400, a flange outer diameter of 3.8 mm, a flange thickness of 0.5 mm, a middle leg diameter of 1.8 mm, and a height of 1.5 mm. A polyurethane-coated copper wire with a wire diameter of 0.16 mm was used as the wire, and the number of windings was 10 turns. Magnetic resin 2 is an epoxy thermosetting resin (product name: S70, Resin Kasei Co., Ltd.) in which magnetic powder 5 is mixed with iron-based amorphous powder at a blending ratio of 40 vol%, and outer periphery 1a of coil 3 and flange portion of drum core 1 are mixed. It applied with a dispenser so that side peripheral part 1b might be covered. The permanent magnet 4 is a disk having a size of φ5 × 3 mm, a neodymium-based rare earth magnet magnetized in the thickness direction and having a magnetic force of 5 Tesla, and is brought into direct contact with the surface 1c of one of the drum cores 1 The drum type inductor of the present invention shown in FIG. 1 was obtained by putting in a bath and drying and curing.

上記の要領で作製した、図１に示した本発明による構造、および比較例として図３に示した従来構造のドラム型インダクタについて、電磁特性および磁性樹脂の剥離強度を測定した結果を表１に示す。なお、上記磁性樹脂の剥離強度は、巻線コイルの巻き始めリードをコイル外周方向に引張った際の剥離強度を測定した。   Table 1 shows the results of measuring the electromagnetic characteristics and the peel strength of the magnetic resin for the structure according to the present invention shown in FIG. 1 and the conventional drum type inductor shown in FIG. Show. The peel strength of the magnetic resin was measured by pulling the lead at the beginning of winding of the winding coil in the coil outer peripheral direction.

Figure 2009004670
Figure 2009004670

表１に示す通り、本発明によるドラム型インダクタの構造では、従来構造と比べ、直流抵抗は殆ど差異はないが、インダクタンスが約３０％以上、また磁性樹脂の剥離強度は約１．７倍も向上していることが分かった。   As shown in Table 1, in the structure of the drum type inductor according to the present invention, the direct current resistance is almost the same as that of the conventional structure, but the inductance is about 30% or more, and the peel strength of the magnetic resin is about 1.7 times. It turns out that it is improving.

更に、永久磁石の磁力によるインダクタンスの影響を確認するため、５テスラと１０テスラの磁力の異なる永久磁石４を用意し、上記の同一要領で作製した、図１に示した本発明のドラム型インダクタについて、各々インダクタンスを測定し比較した結果を表２に示す。   Further, in order to confirm the influence of the inductance due to the magnetic force of the permanent magnet, the permanent magnet 4 having different magnetic force of 5 Tesla and 10 Tesla is prepared, and the drum type inductor of the present invention shown in FIG. Table 2 shows the results of measuring and comparing the respective inductances.

Figure 2009004670
Figure 2009004670

表２に示す通り、本発明によるドラム型インダクタの構造では、配置する永久磁石の磁力の大きい方がより高いインダクタンスを示すことが分かり、永久磁石の強さによってインダクタンス調整が可能であることが分かった。   As shown in Table 2, in the structure of the drum-type inductor according to the present invention, it can be seen that the higher the magnetic force of the permanent magnet arranged, the higher the inductance, and that the inductance can be adjusted by the strength of the permanent magnet. It was.

以上、実施例を用いて、この発明の実施の形態を説明したが、この発明は、これらの実施例に限られるものではなく、この発明の要旨を逸脱しない範囲の設計変更があっても本発明に含まれる。すなわち、当業者であれば、当然なしえるであろう各種変形、修正もまた本発明に含まれる。   The embodiments of the present invention have been described above using the embodiments. However, the present invention is not limited to these embodiments, and the present invention is not limited to the scope of the present invention. Included in the invention. That is, various changes and modifications that can be naturally made by those skilled in the art are also included in the present invention.

本発明のドラム型インダクタにより、携帯電話器等の小型電子機器の低電圧化、大電流化に対応できる小型、低コスト、高性能の平滑用インダクタ市場の構築にも寄与できる。   The drum-type inductor of the present invention can contribute to the construction of a small, low-cost, high-performance smoothing inductor market that can cope with low voltage and large current of small electronic devices such as mobile phones.

本発明のドラム型インダクタとその製造方法を説明する図、図１（ａ）は上面図、図１（ｂ）は断面図、図１（ｃ）は磁性樹脂部の拡大断面図。FIG. 1A is a top view, FIG. 1B is a cross-sectional view, and FIG. 1C is an enlarged cross-sectional view of a magnetic resin portion. 本発明のドラム型インダクタの平均磁路長を説明する図、図２（ａ）は永久磁石を配置しない場合の平均磁路長を説明する図、図２（ｂ）は永久磁石を配置した場合の平均磁路長を説明する図。FIG. 2A is a diagram illustrating the average magnetic path length of the drum-type inductor of the present invention, FIG. 2A is a diagram illustrating the average magnetic path length when no permanent magnet is disposed, and FIG. 2B is a case where a permanent magnet is disposed. The figure explaining the average magnetic path length. 従来のドラム型インダクタを説明する図、図３（ａ）は上面図、図３（ｂ）は断面図、図３（ｃ）は磁性樹脂部の拡大断面図。FIG. 3A is a top view, FIG. 3B is a cross-sectional view, and FIG. 3C is an enlarged cross-sectional view of a magnetic resin portion.

符号の説明Explanation of symbols

１ ドラムコア
１ａ 外周部
１ｂ 鍔部側周部
１ｃ 鍔部表面
２ 磁性樹脂
３ コイル
４ 永久磁石
５ 磁性粉末
６ 樹脂
７ 平均磁路長
８ 磁性樹脂塗布部
Ａ、Ｂ 磁性粉末間距離 DESCRIPTION OF SYMBOLS 1 Drum core 1a Peripheral part 1b Saddle side peripheral part 1c Saddle part surface 2 Magnetic resin 3 Coil 4 Permanent magnet 5 Magnetic powder 6 Resin 7 Average magnetic path length 8 Magnetic resin application part A, B Distance between magnetic powders

Claims (3)

２つの鍔部と、前記鍔部に挟まれた巻線部を有するドラム型磁芯の、前記巻線部にコイルを形成してなるインダクタであって、少なくとも前記コイルの外周部を覆うように磁性粉末と樹脂を混合した磁性樹脂を配してなり、前記磁性樹脂は、前記外周部の前記コイルに近い部分の磁性粉末密度が、前記コイルから離れた部分の磁性粉末密度よりも高いことを特徴とするドラム型インダクタ。   An inductor formed by forming a coil in the winding portion of a drum-type magnetic core having two winding portions and a winding portion sandwiched between the flange portions so as to cover at least the outer peripheral portion of the coil A magnetic resin mixed with magnetic powder and resin is arranged, and the magnetic resin has a magnetic powder density in a portion near the coil in the outer peripheral portion higher than a magnetic powder density in a portion away from the coil. Drum-type inductor that features. ２つの鍔部と、前記鍔部に挟まれた巻線部を有するドラム型磁芯の、前記巻線部にコイルを形成し、少なくとも前記コイルの外周部を覆うように磁性粉末と樹脂を混合した磁性樹脂を配し、前記鍔部の前記コイルの巻線中心軸方向に直交する面上に永久磁石を配した状態で、前記磁性樹脂を硬化したことを特徴とするドラム型インダクタの製造方法。   A drum-type magnetic core having two winding parts and a winding part sandwiched between the hook parts, a coil is formed on the winding part, and magnetic powder and resin are mixed so as to cover at least the outer peripheral part of the coil A method of manufacturing a drum-type inductor, characterized in that the magnetic resin is cured in a state in which the magnetic resin is disposed and a permanent magnet is disposed on a surface of the flange portion perpendicular to the winding central axis direction of the coil. . 前記磁性粉末の特性と、前記磁性粉末と前記樹脂の混合比率と、前記永久磁石の磁気特性から選択された、少なくとも２つの要素を組み合わせることによりインダクタンス特性を調整することを特徴とする請求項２記載のドラム型インダクタの製造方法。   3. The inductance characteristic is adjusted by combining at least two elements selected from characteristics of the magnetic powder, a mixing ratio of the magnetic powder and the resin, and magnetic characteristics of the permanent magnet. The manufacturing method of the drum type inductor as described.
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